Magnetic blocks with improved magnetic properties and construction set thereof

ABSTRACT

The present invention is a magnetic block with improved magnetic properties comprising a non-magnetic body with outer walls and an internal parallelepiped connected by links. Together, they form cells for placing magnets. The magnets are placed such that the distance between adjacent magnets is not greater than the thickness of magnets. Caps are mounted onto the body and thus form a finished block. The ratio of the area of the face of the rectangular magnet to the area of the corresponding face of the block ranges between 0.15 and 0.6. A construction set comprising a plurality of magnetic blocks is also disclosed, wherein the blocks are different colors. Such a design of the magnetic block and the 6 rectangular magnets allows for very high magnetic attraction properties with which one can build geometrically-complex shapes and high-precision objects.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to and incorporates fully byreference U.S. Provisional Patent Application Ser. No. 62/611,606, filedon Dec. 29, 2017.

FIELD OF THE INVENTION

The invention relates to toys, and more particularly to toy buildingblocks having magnetic interaction means, i.e., building blocks heldtogether by magnetic attraction. The present invention also relates togames, e.g., construction set, using building blocks which aremagnetically held together, and which allow creating a variety ofdifferent objects.

BACKGROUND OF THE INVENTION

Different types and designs of magnetic blocks (as items of toyconstruction kits) have been widely known over the years. The generalidea of a magnetic block is based on the following approach. Roundcylindrical magnets are placed inside a block under its surfaces or nearthe ribs of the block. When interacting with each other, the magnetsinside two closely spaced blocks attract and thus the blocks are heldtogether forming a geometrical structure. A variety of prior art patentdocuments describe such magnetic blocks. For example, the followingexemplary prior art is provided: U.S. Patent Application Ser. No.US2015258462, U.S. Patent Application Ser. No. US2015262744,International Application Ser. No. WO2017152483, and Republic of KoreaPatent Application Ser. No. KR20140067453. Such prior art magneticblocks are distinguished by their large outer dimensions andinsignificant magnetic properties. In most cases, the magnets insidesuch prior art blocks are designed only to attract and hold the blocksconnected to each other, in a position where such blocks lay on flatsurfaces. Such prior art blocks are not capable of holding other blocksby weight (i.e., hanging), especially when holding several blocks in arow by weight.

U.S. Patent Application Ser. No. US2015360137 describes a kit for theassembly of a mosaic structure containing an assembly tool to placemulticolored blocks onto at least two interlocking core pieces. Theblocks adhere to the interlocking core pieces or each other by magneticattraction. After the blocks are placed, the interlocking core piecesare secured by engagement of, e.g., a twist-lock connection. With theapplication of a degree of creativity, the assembly kit can be used toform mosaic structures of a sculptural nature that resemble animals,human characters, buildings, and other objects. The assembly kits areparticularly useful in teaching children spatial awareness skills andimproving hand-eye coordination. One disadvantage is the magneticattraction properties of the mentioned blocks are low.

The closest prior art to the present invention are the “MinecraftMagnetic Building Blocks” by Fan and Xi Co. Ltd. (“iFanXi Store,”Yueqing, China). This construction set is designed in a popular styleknown as “Pixel Art”—a form of digital art created through the use ofsmall blocks to make objects look like images at a pixel level. Amagnetic block of the construction set consists of a plastic body madefrom polycarbonates and 6 round NdFeB permanent magnets located in thecenter of each of six panes. Outer dimensions of the block are8.1×8.1×8.1 mm, and the diameter of each magnet is 3.0 mm. An outersurface of the block has a sticker pattern with a Minecraft theme, i.e.,grass, stone, quartz, mud, snow, etc. When one links the building blockstogether, the lateral limit can hold 6 blocks in a row hanging, and thevertical limit is 45 blocks hanging. The main disadvantage of thementioned magnetic blocks is their low magnetic attraction to eachother. The stickers on the outer surfaces of the magnetic block are alsoglued by hand, which is not favorable for batch productions. Over timeand due to frequent use the outer stickers on the blocks are oftenpeeled off and frequently abraded.

Despite the integration of magnets into toy building blocks, users ofthe above-described blocks are limited in how they may align the blocksand the resulting structures (objects) they may create. Long cantileverrows of magnetic blocks and complete freedom for making geometricallycomplex and high-precision constructions are not provided in the priorart. There is a need for a magnetic building block, and morespecifically a set thereof capable of overcoming the aforementionedchallenges. It is necessary to optimize and innovate the internalstructure of small sized (e.g. “Pixel Art”) magnetic blocks and magnetplacement in order to significantly increase their magnetic propertiesand better adapt them for batch productions. The present inventionsolves this need.

SUMMARY OF THE INVENTION

A preferred embodiment of the present invention is a magnetic blockcomprising a plastic body frame and two caps on either (top/bottom) sideof the body frame. Inside the body frame, adjacent to the center of eachface (pane) of the magnetic block, a square magnet is positioned,totaling 6 magnetic pieces per block. The ratio of the area of thesquare magnet to the total area of a corresponding face (pane) is around0.19-0.60 (19%-60%). Each face of the block has a straight facet (i.e.flat edge) and roughness for increasing the friction coefficient. Theinternal ribs of each block are constructed in such a way as to providemaximum strength within the block against compression, excellentresistance to tangential stresses, and to facilitate exact centering ofeach magnet's location in reference to a corresponding face of theblock. Such a design also allows for hiding the seams after assemblingthe magnet block at a production place. The inner design of the magnetblock and specific disposition of the six square magnets allow for ahigh ratio between the magnets' surface area and the block's surfacearea. Such a ratio provides for very high magnetic attractionproperties. A lateral row of the magnetic blocks can have more than 8blocks in a horizontal row hanging (i.e., without any blocks below therow) and the vertical limit is more than 50 blocks hanging.

The present invention also comprises a construction set of theabove-mentioned magnetic blocks of varying colors and/or patterns. Thedifferent colors and/or patterns are used, e.g., to visually distinguisheach block, which allows for creation of visually different parts of thefigures/objects of a construction. Due to the superior magneticproperties of the magnetic blocks of the present invention, one canbuild geometrically complex and high-precision designs/objects.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a general perspective view of a magnetic block according tothe present invention.

FIGS. 2A and 2B show an exploded perspective view diagram with separatedintegral parts of the magnetic block according to the present invention.FIG. 2A shows the body frame, magnets, and two caps. FIG. 2B shows amagnet and the body frame with integral dimensions A, B, C, and D.

FIG. 3 shows a different perspective view of the body frame and a cap ofa magnetic block according to the present invention, such that theinternal frame of the magnetic block is more clearly visible.

FIGS. 4A and 4B show a top view of a magnetic block according to thepresent invention. FIG. 4A shows integral parts of the magnetic block.FIG. 4B shows integral dimensions E and F.

FIG. 5 shows additional features of the internal design of a magneticblock according to the present invention.

FIG. 6 illustrates the magnetic superposition principle that occurs inthe magnetic blocks of the present invention.

FIGS. 7A-7T illustrate possible embodiments of construction setscomprising magnetic blocks according to the present invention.

FIG. 8 shows one embodiment of a magnetic block according to the presentinvention.

FIG. 9 shows another embodiment of a magnetic block according to thepresent invention.

FIG. 10 shows the relative polarities of the faces of a preferredembodiment according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A preferred embodiment of the present invention is a magnetic block (seeFIGS. 1-2) comprising an ABS-plastic body frame 201 appropriate forchildren's toys, two caps 202 for a top and a bottom of the body frame201 and 6 square NdFeB magnets 203 positioned inside the body frame 201along the faces (panes) of the body frame 201. In this embodiment, thesize of the finished block, which comprises the body frame and two caps,is 8.00 mm×8.00 mm×8.00 mm. The size of the body frame is 8.00 mm×8.00mm×7.96 mm. The size of each cap is 7.20 mm×7.20 mm×2.00 mm. Thedimensions of each magnet are 3.80 mm×3.80 mm×1.00 mm. The ratio of thearea of each square magnet 203 (see FIG. 2B) to the total area of thecorresponding face (pane) 204 of the block in this embodiment is around0.225. In certain embodiments, the dimensions of the magnets can be 3.50mm×3.50 mm×1.00 mm. In such embodiments, the same ratio is around 0.19.The block has flat facets (i.e. flat edges) 102 (FIG. 1) having athickness of 0.40 mm, and the thickness of the outer walls 101 (FIG. 1)is 0.40 mm. Such dimensions make it possible to hide the seam linebetween the cap and the body frame of the block. Each cap 202 (FIG. 2)has several pillars 301 and 305 (see FIG. 3) on its inner side forcentral positioning of magnets during an assembly process and properfixation of the cap to the body frame. The internal structure of thebody frame 201 comprises a rectangular hollow parallelepiped 303 (FIG.3) connected with the outer walls 101 (FIGS. 1, 3, 4) of the body framethrough links (i.e. bridges) 401 (FIG. 4). This internal structure ofthe body frame 201 may comprise one continuous element (made, e.g., viaa process similar to die casting). Alternatively, the internal structuremay comprise several elements which are then welded together. The wallsof the inner rectangular parallelepiped 303 (FIG. 3) together with thelinks (bridges) 401 (FIG. 4) form four vertical cells 402 (FIG. 4) forplacing the magnets such that the magnets are located and positionedadjacent the centers of each of the faces of the body frame. The innerspace of the rectangular hollow parallelepiped 303 (FIG. 3) isreinforced with ribs 403 (FIG. 4), the ends of which form two additionalhorizontal cells 404 (FIG. 4—top and bottom) for placement of fifth andsixth magnets adjacent the faces of the upper and lower caps. The innerspace of the rectangular parallelepiped 303 (FIG. 3) may also or insteadbe reinforced with a solid filling. To facilitate the procedure ofassembling the magnet block during production, snap-joints 302 (FIG. 3)are made on each sidewall of the links (bridges) for holding the magnetsin their corresponding cells and preventing them from falling out untilthe caps are mounted. Vertical stiffening ribs 306 are made along theouter sides of the rectangular parallelepiped 303 (FIG. 3). The upperand lower ends of the walls of the rectangular parallelepiped 303 (FIG.3) have a triangular concentrator for ultrasonic welding 501 (FIG. 5).Due to such a design, after welding the caps to the body frame, theseams 502 (FIG. 5) between the caps and the body frame become nearlyinvisible.

The above-mentioned design of the inner structure of the block allowsfor placing the pin gate and the block's ejection places from the mold,inside the block's body frame, thus preventing any traces on the outersurfaces of the block. Due to this design, the block looks like a solidand seamless cube having flat edges after assembly. The vertical magnetcells 402 (FIG. 4) have snap joints 302 (FIG. 3) on the inner sides ofthe cell to hold the magnets in place during the assembly process. It isdesigned in a way that also prevents the formation of creases and otherdeformations on the outer walls of the blocks.

The arrangement and shape of the magnets within the block were chosenexperimentally and based on properties of attraction between blocks andthe overall magnetic field produced by each block. A ratio of thesurface area of the face of a magnet 203 to the surface area of thecorresponding blockface 204 is defined as S-magnet : S-blockface, whereS-magnet=C*D, and where S-blockface=A*B. See FIG. 2B. In a preferredembodiment, this ratio is between 0.19 and 0.60. In other embodiments,the ratio may be as low as 0.15, or between 0.19 and 0.225.Additionally, the distance between the lateral surfaces of adjacentmagnets (see FIG. 4B, element F), in the projection on the plane, ispreferably no greater than the thickness of the magnets themselves (seeFIG. 4B, element E). With such a design, the magnets influence eachother primarily through a change in the demagnetizing factor within thesystem of magnets. Additionally, the magnets are arranged such thatthere are some neighboring magnets with different-facing polarities andothers with same-facing polarities inside each face of the magneticblock. Such an arrangement, for example, creates a block which comprises3 adjacent magnets (and thus three adjacent faces) having a northernoutward facing polarity and three adjacent magnets (and thus threeadjacent faces) having a southern outward facing polarity. See FIGS. 6and 10. This leads to an increase in the magnetic induction on the outeredges of the magnets and further increases the magnetic power of asystem of magnetic blocks when combined. Such an effect also appears(and in fact is further strengthened) when, in addition to thepolarities, the distance between lateral surfaces of magnets (FIG. 4B,element F), in the projection on the plane, is equal to or at least notgreater than 1.3 times the thickness of the magnets (FIG. 4B, elementE).

Since the distance between the magnets on neighboring faces is small,the entire magnetic flux of the inner surface remains in the inner spaceof the block between the magnets. This leads to an increase in themagnetic flux between the outer poles of the magnets and an increase inthe magnetic induction on the surface. The principle of superpositionthat occurs in the proposed block is illustrated in FIG. 6.

Another embodiment of the present invention is a construction setcomprising several magnetic blocks (FIG. 7) having 16 different colors.By joining the blocks together via magnetic attraction, one can create aplurality of different objects. Due to the distinguished magneticproperties of the blocks, complex structures and high precision shapescan be made, being at the same time highly resistant to destruction.Figures from blocks are created by connecting colored blocks one by onein certain sequences. Each block has three adjacent faces with magnetshaving a northern polarity and three adjacent faces with a southernpolarity. The magnetic attraction is sufficiently strong for anautomatic (i.e. self-) attraction of one block to the appropriate faceof another block. In this case, when assembling the figures, one justneeds to bring the block to another block at a short distance andrelease it, and it will turn over to an appropriate face and attach.

In one of the embodiments of the present invention, a multi-polemagnetization of a magnet on one face is used. In other words, half ofthe face of the square magnet is the north pole, and half is the southpole. This allows one to attach blocks not only face-to-face, but alsoat a half-face displacement, which gives additional constructivepossibilities when assembling different figures.

To further enhance the magnetic properties of the blocks, an internalmagnetic core 801 (FIG. 8) may be included, made from a soft-magneticmetal material (for example, low-carbon steel, 0.5 mm). The internalmagnetic core 801 may be located on the inner side of the magnets 802(FIG. 8) inside the block.

Another embodiment of the present invention (FIG. 9) with even bettermagnetic properties comprises a magnetic block comprising a plastic bodyframe with outer walls 901. Inside the body frame is a solidparallelepiped 902. Inner magnets 903 are attached on the outer faces ofthe solid parallelepiped 902. The attachment can be made using any knownmanner, e.g., gluing, welding, pressing, etc. An internal metal core 904may also be integrated inside the solid parallelepiped 902. The ratio ofthe surface area of the face of a rectangular inner magnet 903 to thesurface area of a corresponding face of the block can be up to 0.60(60%) in this case.

Accordingly, it is to be understood that the above-mentioned dimensionsof the embodiment of the invention described are merely illustrative ofthe application of the principles of the invention. The illustrated anddescribed dimensions are not intended to limit the scope of the claims,which themselves recite those features regarded as essential to theinvention. The specified dimensions may be greater or lower whilemaintaining the ratio of the area of the face of a square magnet to thetotal area of the corresponding blockface within the ranges disclosed.

While the foregoing written description of the invention enables one ofordinary skill to make and use what is considered presently to be thebest mode thereof, those of ordinary skill will understand andappreciate the existence of variations, combinations, and equivalents ofthe specific embodiment, method, and examples herein. The inventionshould therefore not be limited by the above described embodiment,method, and examples, but by all embodiments and methods within thescope and spirit of the invention.

The description of a preferred embodiment of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formsdisclosed. Obviously, many modifications and variations will be apparentto practitioners skilled in this art. It is intended that the scope ofthe invention be defined by the following claims and their equivalents.

Moreover, the words “example” or “exemplary” are used herein to meanserving as an example, instance, or illustration. Any aspect or designdescribed herein as “exemplary” is not necessarily to be construed aspreferred or advantageous over other aspects or designs. Rather, use ofthe words “example” or “exemplary” is intended to present concepts in aconcrete fashion. As used in this application, the term “or” is intendedto mean an inclusive “or” rather than an exclusive “or”. That is, unlessspecified otherwise, or clear from context, “X employs A or B” isintended to mean any of the natural inclusive permutations. That is, ifX employs A; X employs B; or X employs both A and B, then “X employs Aor B” is satisfied under any of the foregoing instances. In addition,the articles “a” and “an” as used in this application and the appendedclaims should generally be construed to mean “one or more” unlessspecified otherwise or clear from context to be directed to a singularform.

What is claimed is:
 1. A magnetic block, comprising: a non-magnetic bodyframe comprising four outer walls and an internal parallelepipedconnected to the outer walls of the body frame via links, wherein innerfaces of the outer walls of the body frame, outer faces of the internalparallelepiped, and the links form six cells for placing magnets alongan inner periphery of the magnetic block, rectangular magnets, therectangular magnets being placed one in each of the six cells such thata distance between adjacent magnets, in a projection on the plane, isnot greater than 1.3 times a thickness of each magnet, and at least onecap, the at least one cap being mounted to the body frame, wherein aratio of the surface area of a face of each rectangular magnet to thesurface area of a corresponding face of the magnetic block is between0.15 and 0.60.
 2. The magnetic block of claim 1, wherein the distancebetween adjacent magnets, in a projection on the plane, is equal to orless than a thickness of each magnet.
 3. The magnetic block of claim 1,wherein the ratio is between 0.15 and 0.19.
 4. The magnetic block ofclaim 1, wherein the ratio is between 0.19 and 0.225.
 5. The magneticblock of claim 1, wherein each magnet is positioned adjacent a center ofeach corresponding face of the magnetic block.
 6. The magnetic block ofclaim 1, further comprising flat edges on outer walls of the magneticblock.
 7. The magnetic block of claim 1, further comprising internalribs within the parallelepiped.
 8. The magnetic block of claim 1,wherein seams of an assembled magnetic block are invisible.
 9. Themagnetic block of claim 1, wherein the magnets are NdFeB magnets. 10.The magnetic block of claim 1, wherein each cap comprises one or morepillars on its inner side, said pillars further fixing each cap to thebody frame.
 11. The magnetic block of claim 1, further comprising snapjoints on each sidewall of the links.
 12. The magnetic block of claim 1,further comprising vertical stiffening ribs positioned along the outerfaces of the parallelepiped.
 13. The magnetic block of claim 1, furthercomprising a triangular concentrator for ultrasonic welding.
 14. Themagnetic block of claim 1, wherein three adjacent faces have a northernpolarity and three adjacent faces have a southern polarity.
 15. Themagnetic block of claim 1, wherein at least one face of the magneticblock comprises a multi-pole magnetization.